Continuous process for ethanol production by bacterial fermentation

ABSTRACT

A continuous process for the production of ethanol by fermentation with strains of Zymomonas is provided. Metabolic processes are limited by the nutrients nitrogen, potassium and phosphorus. When growth is limited by one of these nutrients, the biomass expresses its maximum value for both q s  and q p  at any given value of D and S r . The process is conducted at a lower biomass concentration and a higher specific rate of ethanol formation than a similar process conducted with a nutrient medium that is not limited in nitrogen, potassium or phosphorus. A method of improving performance of Zymomonas in continuous ethanol fermentation at increased temperatures is also provided.

BACKGROUND OF THE INVENTION

This invention relates to the bioconversion of a substrate by bacterialfermentation, and more particularly, to a continuous process for theproduction of ethanol by fermentation using strains of Zymomonasbacteria.

Bacterial ethanol fermentation has been known in the art for many years,and in recent years fermentation using strains of Zymomonas mobilis hasreceived increasing attention. The Z. mobilis strains convert a suitablesubstrate, such as glucose or another sugar, to ethanol. Significantlyhigher specific rates of sugar uptake and ethanol production andimproved yield compared to traditional yeast fermentation have beenreported for these Zymomonas strains.

Fermentation by Z. mobilis has been carried out in batch and continuousculture. The fermentation product (ethanol) is dissolved in the liquidmedium in the fermenter. The liquid medium is separated from solids(chiefly biomass) before the ethanol is recovered. Separation of thesetwo phases early in the product-recovery process train is required.Before such a fermentation achieves commercial acceptance, however,productivity must be improved. The reported efforts to date have focusedon developing more productive bacterial strains and modifying theconfiguration of the fermenter used in the fermentation. For example,improvement in ethanol productivity using a continuous culture with acell recycle system has been reported with Z. mobilis strains.

Recovery of the fermentation product can be a complex and multifacetedtask. A significant proportion of the overall cost in a fermentationplant often must be spent for ethanol recovery. A recently reportedtechnique involves the use of a flocculent strain of Z. mobilis thatsettles in the fermenter allowing the supernatant containing the ethanolto be withdrawn while leaving a majority of the cells in the fermenter.This method is based on the well-known gravity sedimentation principlefor separating liquids and solids. The more conventional approaches forseparating fermentation broth from biomass involve the withdrawal of aportion of the culture medium from the fermenter and separation of thetwo phases by centrifugation or filtration techniques. Regardless of thetechnique employed, for a particular ethanol recovery process, it isdesirable to reduce the quantity of biomass in order to reduce the loadof solids on the sedimentation, centrifugation or filtration apparatus.

At the same time, however, the yield of ethanol from the fermentationmust be maximized. Since product formation cannot occur in the absenceof biomass, ethanol formation is dependent on cell mass concentration.In fact, the rate of ethanol production in the fermenter is directlyproportional to the quantity of biomass in the fermenter under steadystate conditions. Thus, within the limits of the metabolic regulatorycontrols of the microorganism and process dynamics, increasing thebiomass in the fermenter while maintaining other conditions constantwill shorten the time required to produce a given amount of ethanol.However, this seemingly simple approach for optimizing processperformance will have an adverse effect on the ethanol recovery processbecause the load of solids on the separating equipment will becorrespondingly increased.

It is well known that the substrate, such as glucose, is the largestitem of raw material cost in the fermentation. Therefore, the presenceof substrate in the effluent from the fermenter is a continuousfermentation is to be avoided. The continuous fermentation should beconducted at optimum process product yield, which occurs when thesubstrate is completely converted to ethanol and when the substrate isminimally diverted from product (ethanol) formation to cell masssynthesis (i.e. when the growth yield with respect to carbon substrateis minimized).

Thus, there exists a need in the art for a continuous process for theproduction of ethanol using strains of Zymomonas in which the substratefed to the fermenter is converted to ethanol in as short a time aspossible. The process should permit a reduction in the quantity ofbiomass in the fermenter in order to obtain a corresponding reduction inthe load of solids on the ethanol recovery apparatus. In addition, thequantity of substrate in the effluent from the fermenter should beminimized.

SUMMARY OF THE INVENTION

This invention aids in fulfilling these needs in the art by providing acontinuous process for the production of ethanol. The present inventionrelates to an improvement in the fermentation performance of strains ofZymomonas in continuous fermentations wherein metabolic processes arelimited by various nutrients, these nutrients being nitrogen, potassiumor phosphorus. When growth is limited by one of these nutrients, thebiomass expresses its maximum value for both specific rate of substrateuptake (q_(s)) and specific rate of product formation (q_(p)) at anygiven value of dilution rate (D) and substrate concentration (S_(r)).One of the criteria for assessing the improvement in performance ofZymomonas according to this invention is the increase in the specificrate of ethanol (product) formation (q_(p)). The response of Zymomonaswith respect to nutrient limitation by nitrogen, potassium or phosphoruscould not be predicted from prior teachings. That Zymomonas expresses amaximal value fo q_(p) (and q_(s)) under conditions of nutrientlimitation was not a predictable phenomenon. The process of thisinvention is conducted at a lower biomass concentration and a higherspecific rate of ethanol formation than a similar process conducted witha nutrient medium that contains the nutrient in excess.

In one embodiment of this invention, a method of improving continuousethanol production by bacterial fermentation with strains of Zymomonasis provided without changing the fermentation temperature. These resultsare achieved by carrying out the fermentation under nutrient-limitingconditions. The limiting nutrient is either nitogen, potassium orphosphorus. The imposition of nutrient limitation makes it possible toconduct the fermentation at a lower biomass concentration at a givensubstrate concentration in the feed stream to the fermenter or at agiven dilution rate than under conditions of nutrient-excess.Consequently, for a given substrate concentration in the feed stream tothe fermenter or a given dilution rate, the fermenter can be operated ata higher specific rate of product formation under the nutrient-limitingconditions than under the nutrient-excess conditions. Moreover, as theconcentrations of substrate in the feed stream is increased or as thedilution rate is increased, the biomass in the fermenter also increases,but the biomass level is less under nutrient-limiting conditions thanunder conditions of nutrient-excess. Furthermore, nutrient-limitationdoes not appreciably affect product yield when compared with a similarfermentation carried out under nutrient-excess; the yield at a givensubstrate concentration in the feed stream or a given dilution rate issubstantially the same under nutrient-limiting conditions as undernutrient-excess conditions. In addition, product yield is substantiallyunaffected under nutrient-limiting conditions when either theconcentration of substrate in the feed stream or the dilution rate isincreased. At the same time, substantially all the substrate isconverted to ethanol; unconverted substrate in the effluent can beavoided.

The amount of the limiting nutrient in the culture medium required toachieve nutrient-limited fermentation according to this invention isproportional to the concentration of substrate in the feed stream to thefermenter and to the dilution rate. In order to maintain a specific rateof product formation, the amount of the limiting nutrient in thefermentation medium must be increased as the concentration of substratein the feed stream is increased. Similarly, when the dilution rate isincreased, the amount of limiting nutrient in the fermentation mediummust be increased to maintain the specific rate of product formation.

In a situation where high cell density is artificially maintained, suchas in a single-stage recycle system, a higher overall productivity couldbe maintained with the nutrient-limited fermentation of this invention.In such a system, the upper limit to the productivity of the fermenteris often determined by the capacity of the recycle device to handle amaximum biomass load. Nutrient limitation results in a reduction in thebiomass level without significantly altering the capacity of thefermenter to handle the same substrate load.

In another embodiment of this invention, a method of improvingperformance of Zymomonas in continuous ethanol fermentation at increasedtemperatures has now been discovered. It has surprisingly been foundthat the specific rate of substrate uptake can be maintained, and evenincreased, at fermentation temperatures of about 33° to about 37° C.even though there is a lower biomass concentration in the fermenter.These results can be achieved without substantial amounts of substratein the effluent from the fermenter. These advantages have a positiveimpact on product recovery and process economics. These results areachieved with this invention by carrying out continuous ethanolfermentation with Zymomonas strains under nutrient-limited conditions,where the limiting nutrient is nitrogen, potassium or phosphorus. Theconcentration of the limiting nutrient in the fermentation medium isincreased with increasing temperature and decreased with decreasingtemperature.

BRIEF DESCRIPTION OF THE DRAWING

The FIGURE is a schematic drawing of fermentation apparatus of the typethat can be employed in practicing the process of this invention.

DETAILED DESCRIPTION

The accompanying FIGURE will provide a background for the followingdiscussion in which the method and apparatus for carrying out thisinvention are described in detail. Referring to the FIGURE, nutrientmedium 1 in reservoir 2 is fed by a pump 3 to a fermenter 4 containing afermentation medium 5. The medium is maintained at a constant volume inthe fermenter by means of an overflow weir 6 that empties into acontainer 7. Carbon dioxide formed during the fermentation is vented at8.

The fermenter 4 is provided with an agitator 9 for mixing the fermentercontents. A pH probe 10 is immersed in the fermentation medium 5 and isconnected to a pH controller 11 for regulating the amount of pHregulating agent 12 in reservoir 13 added by a pump 14 to thefermentation medium 5.

The temperature of the fermentation medium is monitored by temperatureprobe 15. The fermentation medium is heated or cooled as requiredthrough a coil 16 and regulated by the temperature controller 17.

The fermentation medium is formulated so that all but a single essentialnutrient are available in excess of the amount required to synthesize adesired cell concentration. The single growth-limiting nutrient controlsthe size of the steady-state cell population.

Conventional expressions are used throughout this description when thekinetics of the fermentation process are discussed. The abbreviationsidentified in the following list have been used in order to facilittethe discussion. Units of measure have been included where appropriate.

S_(r) =Substrate concentration in the feed stream to the fermenter;g/liter, i.e. g/L.

S_(o) =Substrate concentration in the effluent from the fermenter; g/L.

V=Volume of fermentation medium in the fermenter; L.

X=Concentration of biomass in the fermentation medium (dry basis); g/L.

[P]=Concentration of ethanol in the fermentation medium; g/L.

u=Specific growth rate (mass); hr⁻¹.

D=Dilution rate; hr⁻¹.

N*=Amount of a given nutrient; g.

q_(s) =Specific rate of substrate uptake; g substrate/g biomass-hr⁻¹.

q_(s) ^(max) =Maximum observed specific rate of substrate uptake; gsubstrate/g cell-hr⁻¹.

q_(p) =Specific rate of ethanol formation; g ethanol/g biomass-hr⁻¹.

q_(p) ^(max) =Maximum observed specific rate of ethanol formation; gethanol/g cell-hr⁻¹.

VP=Volumetric Productivity; g ethanol/L-hr⁻¹.

Y_(n) =Growth yield coefficient for a specified limiting nutrient, n; gdry biomass/g-atom nutrient.

n=Limiting nutrient, i.e., nitrogen, potassium or phosphorus.

Y_(p/s) =Product Yield Coefficient=q_(p) /q_(s) ; g ethanol produced/gsubstrate consumed.

Y_(x/s) =Growth yield coefficient; g biomass/g-atom of substrateconsumed.

YE=yeast extract (Difco) in aqueous medium; g/L.

AC=High grade anhydrous NH₄ Cl in aqueous solution; g/L.

AS=High grade anhydrous (NH₄)₂ SO₄ in aqueous solution; g/L.

Eth=ethanol

Glu=glucose

Nutrient-Limited Fermentation

As used herein, the expression "nutrient-limited fermentation" andsimilar expressions mean a fermentation of an organic substrate by aZymomonas strain, where the fermentation is carried out in a continuousprocess under steady-state conditions in a medium in which one or morenutrients are present in an amount such that the rate of growth islimited by the availability of one or more of the essential nutrients.

As used herein the expression "limiting nutrient" means nitrogen,potassium or phosphorus.

The process of this invention is carried out as a continuousfermentation. The term "continuous" is used in its conventional senseand means that nutrients are fed to a fermenter substantiallycontinuously and that an output, or effluent, stream is substantiallyconstantly withdrawn from the fermenter. The nutrient stream usuallycomprises an aqueous organic substrate solution. The effluent streamcomprises biomass and the liquid phase from the fermentation medium.

Fermentation can be carried out in a bioreactor, such as a chemostat,tower fermenter or immobilized-cell bioreactor. Fermentation ispreferably carried out in a continuous-flow stirred tank reactor. Mixingcan be supplied by an impeller, agitator or other suitable means andshould be sufficiently vigorous that the vessel contents are ofsubstantially uniform composition, but not so vigorous that themicroorganism is disrupted or metabolism inhibited.

Fermentation is carried out with a submerged culture and undersubstantially anaerobic conditions. While the invention is described inthe Examples hereinafter with freely mobile cells, it will be understoodthat immobilized cells can also be employed. The fermenter is preferablyenclosed and vented to allow the escape of carbon dioxide evolved duringthe fermentation. Oxygen at the surface of the fermentation medium is tobe avoided. This may inherently occur as the heavier carbon dioxideevolved during the fermentation displaces the oxygen in the gas phaseabove the medium. If necessary, the gas phase above the medium can bepurged with an inert gas to remove oxygen and maintain substantiallyanaerobic conditions.

The fermenter can be operated with or without cell recycle. Cell recyclemakes it possible to increase the productivity of the system byoperating at a higher steady-state cell concentration compared to asimilar system without cell recycle. When cell recycle is employed, aportion of the fermenter contents is withdrawn from the fermenter, theethanol-containing phase is separated from the effluent, and theresulting concentrated cells are returned to the fermenter. Theseparation is typically carried out by microfiltration orcentrifugation. Since the process of this invention is carried out atreduced biomass concentration in the fermenter, the load of solids onthe cell recycle apparatus is reduced and ease of ethanol recovery isincreased.

The composition of the effluent stream can vary and will usually be thesame as the composition of the fermentation medium. When a flocculentstrain of Zymomonas is employed, however, or if partial separation ofbiomas from the liquid phase otherwise occurs in the fermenter, theeffluent can contain a larger proportion of biomass or liquid phasedependding upon the location where the efflent is withdrawn from thefermenter.

The microorganism employed in the process of this invention is agram-negative, faculative anaerobic bacterium of the genus Zymomonascapable of fermenting an organic substrate to ethanol under substaniallyanaerobic continuous culture conditions. Typical strains are Zymomonasmobilis and Zymomonas anaerobia. Suitable strains of Zymomonas areavailable from microorganism depositories and culture collections.Examples of suitable Z. mobilis strains are those identified as ATCC10988, ATCC 29191, ATCC 31821 and ATCC 31823 [ex ATCC 31821]. Examplesof other strains of Z. mobilis are those identified as NRRL B-14023 [CP4] and NRRL B-14022 [CP 3]. Flocculent strains can also be employed.These strains include ATCC 35001 [ex ATCC 29191], ATCC 35000 [x NRRLB-14023], ATCC 31822 [x ATCC 31821], and NRRL B-12526 [x ATCC 10988]. Z.mobilis strains are occasionally referred to in the literature by thefollowing alternate designations:

                  TABLE 1                                                         ______________________________________                                        Culture Collection                                                            Accession No.      Literature Designation                                     ______________________________________                                        ATCC 10988         Strain ZM 1                                                ATCC 29191         Strain ZM 6 (or Z6)                                        ATCC 31821         Strain ZM 4                                                ATCC 31822         Strain ZM 401                                              ATCC 31823         Strain ZM 481                                              NRRL B-14022       Strain CP3                                                 NRRL B-14023       Strain CP4                                                 ______________________________________                                    

It will be understood that other Zymomonas strains can be obtained byselective cultivation or mutation as well as by genetic engineeringtechniques to provide microorganisms with desired metabolic properties.

The substrate employed in the process of this invention is an organic,fermentable sustrate for the Zymomonas strain. As the carbon source forboth the growth and fermentation stages of the process, variouscarbohydrates cand be employed. Examples of suitable carbohydrates aresugars, such as glucose, fructose and sucrose; molasses; starchhydrolysates; and cellulose hydrolysates. Other suitable substrates willbe apparent to those skilled in the art. The organic substrate can beemployed either singly or in admixture with other organic substrates.

The substrate is fed to the fermenter in aqueous solution. Theconcentration of organic substrate in the fermentation medium willdepend upon the culture conditions. The substrate is employed in anamount sufficient for cell growth and product formation. Typically, theconcentration of fermentable substrate in the feed stream to thefermenter will be about 100 to about 180 g/L.

The flow rate of the substrate solution to the fermenter will dependupon the size and configuration of the fermenter, the amount of biomassin the fermenter and the rate at which substrate is consumed, and can bedetermined with a minimum of experimentation. The flow rate should bebelow the rate at which a substantial amount of substrate appears in theeffluent from the fermenter. Preferably, the flow rate of the substratesolution to the fermenter should be such that the effluent substrateconcentration is less than about5% S_(r), and should be such that theeffluent is substantially free of substrate under optimum operatingconditions.

The process of this invention can be carried out over a moderate rangeof temperatures. The effects of temperature changes on fermenterperformance are discussed below, but generally speaking, the process ofthis invention is carried out at a temperature of about 27° C. to about37° C., preferably about 30° C.

Zymomonas fermentations have been reported at pH values ranging fromabout 4 to about 8 in the culture medium. The process of this inventioncan be carried out over a moderate range of pH values in the culturemedium, but rapid metabolism of the organic substrate with high productyield occurs over a narrower range. The process of this invention ispreferably carried out at a pH of about 4.5 to about 6.5. At pH valuesabove about 6.5, product yield decreases and the formation ofundesirable products increases. The particularly preferred pH is about5.5, which was the pH used in all of the fermentations described herein.

The pH in the culture medium often falls and rises during thefermentation. To restrict pH changes during fermentation, the medium canbe buffered. In addition, the pH of the medium can be intermittently orcontinuously monitored and acidic or basic substances added to adjust pHduring the course of fermentation. A buffering agent or a pH regulatingagent that is non-toxic and substantially non-inhibitory to themicroorganism can be employed for this purpose. The pH regulating agentis typically a hydroxide or an organic or inorganic acid. Examples ofsuitable pH regulating agents are potassium hydroxide, sodium hydroxideand hydrochloric acid.

The process of this invention is carried out under sufficiently sterileconditions to ensure cell viability and metabolism. This requirescareful selection of the microorganism, sterilization of the apparatusfor the fermentation and of the liquid and gaseous streams fed to thefermenter. Liquid streams can be sterilized by several means, includingradiation, filtration and heating. Small amounts of liquids containingsensitive vitamins and other complex molecules can be sterilized bypassage through microporous membranes. Heat-treatment processes arepreferred for sterilizing the substrate feed stream and can be carriedout by heating the stream in a batch or continuous flow vessel. Thetemperature must be high enough to kill essentially all organisms in thetotal holding time. Water utilized in the preparation of the substratesolution and in the preparation of the fermentation broth in thefermenter can be sterilizer in a similar manner or by other conventionaltechniques.

After the fermenter has been inoculated with the Zymomonasmicroorganism, the quantity of biomass is multiplied. The growingculture is allowed to complete the lag phase and substantially theentire exponential phase of growth before flow to the fermenter isinitiated. The fermentation is allowed to proceed under substantiallysteady state conditions with the continuous introduction of freshsubstrate and the continuous withdrawal of product from the fermenter.While product formation is not solely associated with growth, it will beunderstood that a portion of the substrate fed to the fermenter goesinto cell maintenance. Thus, in the case of direct conversion of glucoseto ethanol

1 mole glucose→2 moles ethanol +2 moles CO₂. The maximum conversion is 2mole ethanol per mole glucose or 0.51 g ethanol/g glucose, buttheoretical yield cannot be achieved in practice since some of thesubstrate goes into cell mass. The process of this invention is carriedout at a yield of at least about 80%, preferably at least about 94%, oftheoretical yield. In this context, complete fermentation means thatgreater than 95% of the sugar substrate has been converted to ethanolproduct.

Viable cell concentration in the fermenter will depend upon severalfactors, such as dilution rate, substrate concentration, maximum growthrate and growth yield coefficient. The fermenter can be operated over arange of biomass concentrations and the optimum concentration can bedetermined without undue experimentation. The practical range of valueswill generally depend upon process economics. For example, a continuouschemostat culture without cell recycle at maximum substrateconcentration in the feed stream can typically be operated at a maximumbiomass concentration (DWB) of about 3.5 g/L. A practical range ofbiomass concentrations is about 0.8 to about 3.2 g/L.

The concentration of ethanol in the fermentation medium should bemaximized in order to reduce the cost of product recovery. The processof this invention is carried out at ethanol concentrations up to about85 g/L, preferably about 28 g/L to about 70 g/L, especially about 50 g/Lto about 60 g/L, in the fermentation medium.

Z. mobilis is sensitive to ethanol concentration, and at concentrationsin excess of about 50 g/L (5% w/v), at T≦33° C. cell growth andmetabolism are retarded. This can be caused by a high concentration ofsubstrate in the feed steam to the fermenter. Thus, as the value forS_(r) is increased, the maximum dilution rate for substantially completeconversion of substrate to ethanol should be decreased. The process ofthis invention is carried out at a dilution rate of about 0.05 hr⁻¹ toabout 0.35 hr⁻¹, preferably about 0.1 hr⁻¹ to about 0.2 hr⁻¹.

These features of this invention will be more fully understood from thefollowing discussion. The effects of the limiting nutrient on fermenerperformance at various concentrations of substrate in the feed streamand different dilution rates are summarized below. The results obtainedin a series of experiments with varying operating conditions arereported in the following Tables.

Nitrogen-Limited Fermentation

Table 2 shows the effect of increasing the concentration of glucose inthe feed stream on the performance of a continuous fermentation of Z.mobilis strain ATCC 29191 in a chemostat at a constant dilution rate of0.15 hr⁻¹ under either nitrogen-limiting conditions or conditions ofnitrogen-excess. The amount of assimilable nitrogen was varied bychanging the amount of either yeast extract (YE), ammonium chloride (AC)or ammonium sulphate (AS). The amount of the nitrogen-limiting additivewas the minimal amount required to achieve maximal rate of sugarutilization and ethanol production by the Z. mobilis strain under thefermentaion conditions.

                  TABLE 2                                                         ______________________________________                                        Amount of Assimilable Nitrogen as either Yeast Extract                        (Difco), Ammonium Chloride or Ammonium Sulphate Required                      to Achieve Maximal Rate of Sugar Utilization and Ethanol                      Production by Z. mobilis ATCC 29191 in Continuous Culture                     at Fixed Dilution Rate (0.15 hr.sup.-1) as a Function of                      Feed Sugar Concentration (S.sub.r)                                            Excess Nitrogen  Nitrogen Limitation                                          S.sub.r                                                                            [P]    X                X            YE   AC   AS                        g/L  g/L    g/L    q.sub.s                                                                            q.sub.p                                                                            g/L  q.sub.s                                                                           q.sub.p                                                                           g/L  g/L  g/L                       ______________________________________                                         20  9.6    0.58   5.2  2.5  0.36 8.3 3.9 0.8  0.19 0.23                       60  28     1.73   5.2  2.5  1.1  8.3 3.9 2.4  0.59 0.72                      110  52     3.17   5.2  2.5  2.0  8.3 3.9 4.4  1.10 1.32                      ______________________________________                                         Units:                                                                        q.sub.s = g glu/g cellhr.sup.l ;                                              q.sub.p = g eth/g cellhr.sup.-1.                                         

The data in Table 2 show that a fermenter can be operated according tothis invention at a lower biomass concentration under nitrogen-excess ata given glucose concentration. For example, with a glucose concentration(S_(r)) of 20 g/L in the feed stream, the biomass concentration (X) inthe fermenter was only 0.36 g/L under nitrogen-limiting conditions,whereas the biomass concentration was 0.58 g/L under conditions ofnitrogen-excess. A similar comparison can be made for the other glucoseconcentrations shown in Table 2.

The data in Table 2 also show that the fermenter can be operated at ahigher specific rate of product formation (q_(p)) undernitrogen-limiting conditions than under conditions of nitrogen-excess ata given glucose concentration. The observed specific rate of productformation of 3.9 under nitrogen-limiting conditions was approximately1.56 times greater than observed q_(p) under conditions ofnitrogen-excess.

In addition, the data in Table 2 demonstrate that as the concentrationof glucose in the feed stream (S_(r)) is increased, biomassconcentration (X) also increases under both nitrogen-limiting andnitrogen-excess conditions, but the biomass level is less undernitrogen-limiting conditions than under conditions of nitrogen-excessfora given S_(r).

For near complete conversion of glucose to ethanol, the amount oflimiting nitrogen was increased as the glucose concentration wasincreased. For example, in order to achieve complete fermentation ofadded substrate, the quantity of yeast extract in the nutrient mediumwas increased from 0.8 g/L to 4.4 g/L when the glucose concentration inthe feed stream was increased from 20 g/L to 110 g/L. The cultureexpressed maximal values for q_(p) and q_(s) under these conditions.

The data in Table 2 also show that nitrogen-limitation in thefermentation medium does not appreciably affect product yield whencompared with a similar fermentation carried out under conditions ofnitrogen-excess. The product yield was about 92% of the theoreticalmaximum yield in all cases. [[e.g., [28/(60×0.51)]×100=92%]]. Theseresults were entirely unexpected.

Another series of fermentations similar to those summarized in Table 2was carried out, except that the concentration of glucose in the feedstream (S_(r)) to the fermenter was maintained at 110 g/L while thedilution rate (D) was varied. Table 3 shows the amount of assimilablenitrogen as either yeast extract (YE), ammonium chloride (AC) orammonium sulphate (AS) required to achieve maximal rate of sugarutilization and ethanol production under nitrogen-limiting conditionsand conditions of nitrogen-excess.

                  TABLE 3                                                         ______________________________________                                        Amount of Assimilable Nitrogen as either Yeast Extract (Difco)                Ammonium Chloride or Ammonium Sulphate Required to                            Achieve Maximal Rate of Sugar Utilization and Ethanol Pro-                    duction by ATCC 29191 in Continuous Culture at Fixed Feed                     Glucose Z. mobilis Concentration (S.sub.r = 110 g/L) as a Function            of the Dilution Rate (D)                                                      Excess                                                                        Nitrogen       Nitrogen Limitation                                            D    S.sub.r                                                                              X              X            YE   AC   ASS.sub.o                   hr.sup.-1                                                                          g/L    g/L    q.sub.s                                                                           q.sub.p                                                                           g/L  q.sub.s                                                                           q.sub.p                                                                           g/L  g/L  g/L g/L                     ______________________________________                                        0.1  110    2.53   4.4 2.1 1.33 8.3 3.9 3.0  0.71 0.88 5                      0.15 110    3.17   5.2 2.5 2.00 8.3 3.9 4.4  1.07 1.32 5                      0.2  110    3.63   6.1 2.9 2.65 8.3 3.9 5.9  1.42 1.74 5                      0.2  110                   2.00 8.3          1.07 30                          ______________________________________                                         Units:                                                                        q.sub.s = g glu/g cellhr.sup.31 1 ;                                           q.sub.p = g eth/g cellhr.sup.-1.                                         

The data in Table 3 demonstrate that a fermenter can be operatedaccording to this invention at a lower biomass concentration undernitrogen limiting conditions than under conditions of nitrogen-excess ata given dilution rate. The fermenter can be operated at a higherspecific rate of product formation under nitrogen-limiting conditionsthan under conditions of nitrogen-excess at a given dilution rate. Asthe dilution rate is increased, biomass concentration in the fermenteralso increases with increasing amounts of nitrogen, but the biomasslevel is less under nitrogen-limitation than under nitrogen-excess.

The amount of assimilable nitrogen required for nitrogen-limitedfermentation is proportional to the dilution rate and must be increasedas the dilution rate is increased to achieve complete substrateconversionto ethanol. The significance of this feature of the inventioncan be more fully appreciated by comparing the data in Table 3. When thefermentation was carried out under nitrogen-limiting conditions and thedilution rate was doubled, say from 0.1 hr⁻¹ to 0.2 hr⁻¹, the amount ofammonium chloride (AC), or its equivalent, had to be about doubled,e.g., from 0.71 to 1.42, in order to ensure substantially completefermentation of the glucose substrate. By comparison, when the amount ofassimilable nitrogen as ammonium chloride was maintained at 1.0 g/Lwhile the dilution rate was increased 0.15 hr⁻¹ to 0.2 hr⁻¹, the biomassconcentration in the fermenter remained constant at 2.00 g/L, but thefermentation was incomplete as evidenced by the appearance ofunfermented glucose in the fermenter effluent. The glucose concentrationin the effluent (S_(o)) increased from a level of less than 0.5% (w/v)to a level of about 3.0%(w/v) when the concentration of assimilablenitrogen was not adequately controlled.

Nitrogen limitation according to this invention does not appreciablyaffect the efficiency of conversion of substrate to ethanol, expressedas the amount of ethanol produced per amount of substrate utilized,rather than the amount of ethanol produced per the amount of substrateadded to the fermenter. In the fermentations reported in Table 3 thatwere carried out according to this invention, the observed ethanolconcentration was about 52 g/L. This corresponded to a product yield ofabout 93% of the theoretical maximum yield.

Under conditions of excess-nitrogen, the specific rate of glucose uptakeand the specific rate of ethanol production increases with increasingdilution rates. In the case of nutrient-limited fermentation, thebiomass expresses maximal rate of sugar uptake and maximal rate ofethanol production. The rates are higher in all cases withnutrient-limitation than with nutrient-excess. The data in Table 3 showthat a more pronounced effect on the specific rate of glucose uptake andthe specific rate of product formation can be obtained at lower dilutionrates by carrying out the fermentation under nitrogen-limitingconditions according to this invention.

Data demonstrating that there is typically a maximum imposed on both theconcentration of glucose in the feed stream (S_(r)) to the fermenter andthe dilution rate (D) when complete conversion (95% or more) of sugar toethanol is desired at relatively high ethanol concentrations can befound in Table 4.

                  TABLE 4                                                         ______________________________________                                        Amount of Assimilable Nitrogen as Either Yeast Extract (Difco)                Ammonium Chloride or Ammonium Sulphate Require to Achieve                     Maximal Rate of Sugar Utilization and Ethanol Production                      by Z. mobilis ATCC 29191 at High Product Concentration                        D = 0.08 hr.sup.-1                                                            Excess Nitrogen  Nitrogen Limitation                                          S.sub.r                                                                            Eth    X                X            YE   AC   AS                        g/L  g/L    g/L    q.sub.s                                                                            q.sub.p                                                                            g/L  q.sub.s                                                                           q.sub.p                                                                           g/L  g/L  g/L                       ______________________________________                                        150  67     2.16   5.1  2.4  1.37 8.3 3.9 3.1  0.73 0.90                      ______________________________________                                         Units:                                                                        q.sub.s = g glu/g cellhr.sup.-l ;                                             q.sub.p = g product/g cellhr.sup.-1.                                     

When the concentration of glucose in the feed stream was elevated to 150g/L, the maximum dilution rate that could be maintained for completefermentation was 0.08 hr⁻¹. The ethanol concentration in thefermentation medium was 67 g/L for this glucose level. Table 4 comparesthe results for nitrogen-limited fermentation according to thisinvention with fermentation carried out under conditions ofnitrogen-excess. The data show that even with a high concentration ofsugar in the feed stream and a high ethanol concentration in thefermentation medium, this invention makes it possible to operate at areduced biomass level, an increased rate of substrate uptake and anincreased rate of product formation.

Potassium-Limited Fermentation

This invention can also be carried out by potassium-limited fermentationof Zymomonas in continuous culture in a manner analogous to thenitrogen-limited fermentation previously described and with comparableresults. The range of tolerable amounts of potassium in the nutrientmedium is rather narrow. For this reason, and for the additional reasonthat the amount of the limiting nutrient must be known with substantialprecision, potassium-limited fermentation is conducted in a definedsalts medium. An example of a suitable medium is described hereinafterwith reference to Table 7.

The amount of potassium, as potassium chloride, required to achievemaximum rate of sugar utilization and ethanol production by Z. mobilsstrain ATCC 29191 in continuous culture in a chemostat at fixed dilutionrate of 0.15 hr⁻¹ was determined as a function of feed sugarconcentration. The results are reported in Table 5.

                  TABLE 5                                                         ______________________________________                                        Amount of Potassium (as Potassium Chloride) Required to                       Achieve Maximal Rate of Sugar Utilization and Ethanol Pro-                    duction by Z. mobilis ATCC 29191 in Continuous Culture at Fixed               Dilution Rate (0.15 hr.sup.-1) as a Function of Feed Sugar                    Concentration D = 0.15 hr.sup.-1                                                     Excess Potassium                                                                           Potassium Limitation                                      S.sub.r                                                                             Eth    X                  X              KCl                            g/L   g/L    g/L     q.sub.s                                                                            q.sub.p                                                                             g/L  q.sub.s                                                                            q.sub.p                                                                            g/L                            ______________________________________                                        20    9.6    0.58    5.2  2.5   0.40 7.5  3.6  0.024                          60    28     1.73    5.2  2.5   1.2  7.5  3.6  0.071                          110   52     3.17    5.2  2.5   2.2  7.5  3.6  0.129                          ______________________________________                                         Units:                                                                        q.sub.s = g glu/g cellhr.sup.-1 ;                                             q.sub.p = g eth/g cellhr.sup.-1.                                         

As shown in Table 5 and as in the nitrogen-limited fermentation,potassium-limited fermentation can be carried out at lower biomassconcentration than under conditions of potassium-excess at a givenglucose concentration. Also, the fermenter can be operated at a higherq_(p) under potassium-limitation than under potassium-excess at a givenglucose concentration. As glucose in the feed is increased, biomass inthe fermenter also increases, but the biomass level is less underpotassium-limitation than under potassium-excess. As withnitrogen-limited fermentation, the amount of potassium required forpotassium-limited fermentation is proportional to the concentration ofglucose in the feed stream; the amount of potassium as KCl must beincreased as glucose concentration is increased to maintain q_(p). Onceagain, the nutrient limitation does not appreciably affect product yieldwhen compared with a similar fermentation carried out undernutrient-excess.

When this invention is carried out with potassium-limited fermentationand when it is necessary to control the pH of the fermentation medium, apH regulating agent or buffering agent other than potassium hydroxide orother potassium-containing compound should be employed, otherwise it ispractically impossible to control the amount of potassium in thefermentation medium. The use of sodium hydroxide as the pH regulatingagent in a potassium-limited fermentation has been found to beadvantageous. Sodium apparently acts as a potassium antagonist, and theresulting elevated level of sodium after the addition of sodiumhydroxide to the fermenter potentiates the effect ofpotassium-limitation on the specific activity of the biomass. Abuffering agent, such as NaH₂ PO₄, can also be employed.

Phosphorus-Limited Fermentation

This invention can be carried out by phosphorus-limited fermentation ofZymomonas in continuous culture in a manner analogous to thenitrogen-limited fermentation previously described and with comparableresults. As with potassium-limited fermentation, the range of tolerableamounts of phosphorus in the nutrient medium is rather narrow. For thisreason, and for the additional reason that the amount of the limitingelement must be known with substantial precision, phosphorus-limitedfermentation is conducted in a defined salts medium. Once again, anexample of a suitable medium is described hereinafter with reference toTable 7.

The amount of assimilable phosphorus as potassium dihydrogen phosphaterequired to achieve maximal rate of sugar utilization and ethanolproduction by Zymomonas mobilis strain ATCC 29191 in continuous culturein a chemostat at fixed dilution rate of 0.15 hr⁻¹ was determined as afunction of feed sugar concentration. The amount of potassium dihydrogenphosphate employed and the results obtained are reported in Table 6.

                  TABLE 6                                                         ______________________________________                                        Amount of Assimilable Phosphorus, as KH.sub.2 PO.sub.4, Required to           Achieve Maximal Rate of Sugar Utilization and Ethanol                         Production by Z. mobilis ATCC 29191 in Continuous Culture                     at Fixed Dilution Rate (0.15 hr.sup.-1) as a Function of Feed                 Sugar Concentration                                                           D = 0.15 hr.sup.-1                                                                   Excess Phosphate                                                                           Phosphate Limitation                                      S.sub.r                                                                             Eth    X                  X             KH.sub.2 PO.sub.4               g/L   g/L    g/L     q.sub.s                                                                            q.sub.p                                                                             g/L  q.sub.s                                                                            q.sub.p                                                                           g/L                             ______________________________________                                        20    9.6    0.58    5.2  2.5   0.42 7.2  3.4 0.04                            60    28     1.73    5.2  2.5   1.25 7.2  3.4 0.13                            110   52     3.17    5.2  2.5   2.29 7.2  3.4 0.23                            ______________________________________                                         Units:                                                                        q.sub.s = g glu/g cellhr.sup.-1 ;                                             q.sub.p = g eth/g cellhr.sup.-1.                                         

The data in Table 6 show that the results obtained withphosphorus-limited fermentation are analogous to the results obtainedwith nitrogen-limited and potassium-limited fermentations.Phosphorus-limited fermentation can be carried out at lower biomassconcentration, higher specific rate of glucose uptake, higher specificrate of product formation and comparable product yield as compared tofermentation carried out under conditions of phosphorus-excess. The datashow that the amount of phosphorus required for phosphorous-limitedfermentation is proportional to the concentration of glucose in the feedstream.

When this invention is carried out with phosphorus-limited fermentationand when it is necessary to control the pH of the fermentation medium, apH regulating agent or buffering agent other than aphosphorus-containing compound should be employed. The additional sourceof phosphorus from a phorphorus-containing pH regulating agent mayprevent the degree of control of nutrient-limitation required by theinvention. For phosphorus-limited fermentation KH₂ PO₄ can be employedas a buffer and NaOH titrant diluted to 0.5N in order to avoid largechanges in pH during automatic titration.

Formulating the Nutrient Medium

The identity of the chemical constituents in the nutrient medium and theamount of each constituent should be sufficient to meet the elementalrequirements for cell mass and ethanol production and should supplyappropriate energy for synthesis and maintenance. The nutrient mediumshould contain carbon, nitrogen, potassium, phosphorus, sulfur,magnesium, calcium and iron in required amounts. The chemicalconstituents should also meet specific nutrient requirements includingvitamins and trace minerals.

As the assimilable source of nitrogen, various kinds of inorganic ororganic salts or compounds can be included in the nutrient medium. Forexample, ammonium salts, such as ammonium chloride or ammonium sulfate,or natural substances containing nitrogen, such as yeast extract,peptone, casein hydrolysate or corn steep liquor, or amino acids, suchas glutamic acid, can be employed. These substances can be employedeither singly or in combination of two or more.

Examples of inorganic compounds that can be included in the culturemedium are magnesium sulfate, potassium monohydrogen phosphate,potassium dihydrogen phosphate, sodium chloride, magnesium sulfate,calcium chloride, iron chloride, magnesium chloride, zinc sulfate,cobalt chloride, copper chloride, borates and molybdates.

Organic compounds that may be desirable in the fermentation include, forexample, vitamins, such as biotin, calcium pantothenate, and the like,or organic acids, such as citric acid, or amino acids, such as glutamicacid. It has been found, however, that biotin is not required in thegrowth medium.

Fermentation aids that are non-toxic to the microorganism can beincluded in the nutrient medium and fermentation broth. For example, ananti-foaming agent in a minor amount has been found to be advantageous.

Examples of nutrient media that have been found suitable for use in thisinvention are described in Table 7.

                  TABLE 7                                                         ______________________________________                                        Chemical Composition of Growth Media for                                      Continuous Culture of Z. mobilis                                                          SEMI-SYNTHETIC DEFINED                                                        MEDIUM         SALTS MEDIUM                                       INGREDIENT  (g/L)          (g/L)                                              ______________________________________                                        D-Glucose   100            100                                                (anhydrous) approx.                                                           Yeast Extract                                                                             5              --                                                 (Difco)                                                                       NH.sub.4 Cl 2.4            2.4                                                KH.sub.2 PO.sub.4                                                                         3.48           3.48                                               MgSO.sub.4.7H.sub.2 O                                                                     1.0            1.0                                                FeSO.sub.4.7H.sub.2 O                                                                     0.01           0.01                                               Citric Acid 0.21           0.21                                               Vitamins                                                                      Ca-pantothenate                                                                           0.001          0.001                                              Biotin      0.001          0.001                                              Antifoam                                                                      as required                                                                   ______________________________________                                    

The semi-synthetic medium is suitable for use in the nitrogen-limitedfermentation according to this invention. It will be understood that thecomposition of this medium will depend on the technical quality of thenitrogen source. For example, yeast extract from a batch from onecommercial source may exhibit a different potency with respect to thecontent of assimilable nitrogen than a yeast extract from a differentbatch or from another commercial source. Also, the amount of thenitrogen source required in the medium will depend on the degree ofhydration; anhydrous chemicals are preferred and were employed in theExamples and in the fermentations reported in the Tables.

The defined salts medium is suitable for use in carrying out thepotassium-limited and phosphorus-limited fermentations. Only inorganicsources of nitrogen, such as ammonium salts, are employed in definedsalts media. In the experiments reported in the foregoing Tables andExamples, the defined salts medium was used in the potassium- andphosphorus-limited fermentations, with the following exceptions.

Ordinarily, the phosphorus in the nutrient medium is supplied as a salthaving an anion that is substantially non-toxic to the microorganism andthat does not substantially inhibit normal metabolic processes. While apotassium salt, such as potassium dihydrogen phosphate, is typicallyemployed for nitrogen-limited and phosphorus-limited fermentations, asodium salt is preferably substituted for the potassium salt inpotassium-limited fermentation. For example, sodium dihydrogen phosphateinstead of potassium dihydrogen phosphate can be utilized. Since theamount of available potassium must be precisely known underpotassium-limited conditions, this substitution makes it easier tocontrol the relative proportions of nutrients.

The potassium in the nutrient medium for potassium-limited fermentationis supplied by a salt having an anion that is substantially non-toxic tothe microorganism and that does not substantially inhibit normalmetabolic processes. The source of potassium is preferably potassiumchloride, although similar water-soluble, inorganic salts can beemployed.

The amount of limiting nutrient in the nutrient medium mainly depends ontwo factors: The concentration of substrate in the feed stream to thefermenter and the dilution rate. As the substrate concentration at aconstant dilution rate is increased, the amount of limiting nutrient isincreased. Similarly, at a constant substrate concentration, the amountof limiting nutrient is increased as the dilution rate increases. Theserelationships apply to nitrogen-limited, potassium-limited andphosphorus-limited fermentations, since the fermentations are analogousto each other. The concentrations of inorganic salts other than the N-,K- and P-containing salts are relatively invariant with the formulationsshown in Table 7.

The nutrient media in Table 7 can also be employed in a fermentationcarried out under conditions of nutrient excess. For example, anitrogen-excess medium based on yeast extract (Difco) and ammonium ioncan contain about 5 to about 10 g/L of the yeast extract and about 15 toabout 34 mM, preferably about 30 mM, ammonium ion. Molar values aregiven because the weight depends on the particular ammonium salt chosen.For ammonium chloride the corresponding concentrations would be about0.8 to about 2.4 g/L, preferably about 1.6 g/L. The nutrient medium usedin the fermentations carried out under conditions of nitrogen excess andreported in Tables 2, 3 and 4 was the semisynthetic medium of Table 7containing 5 g/L yeast extract (Difco) and 1.6 g/L NH₄ Cl.

The amount of limiting nutrient, namely nitrogen, potassium orphosphorus, expressed as the concentration in the growth medium beingfed to the fermenter, required to achieve a condition of growthlimitation can be determined from Equations (1) and (2) and a knowledgeof values for the growth yield with respect to the particular limitingnutrient and the maximum specific rate of substrate utilization (q_(s)^(max)). While these values may be strain specific, they can beexperimentally determined and examples are given below.

The equations used to calculate the amount of limiting nutrient requiredto achieve a condition of nutrient deficiency or limitation are:

    N*=X*/Y.sub.n                                              (1)

where

N*=the amount of source of nutrient, g;

X*=the dry mass of cells (dry wt biomass), g; and

Y_(n) =growth yield coefficient for a specified limiting nutrient, n; gdry biomass/g-atom nutrient source (see Table 9).

The value for X* in Equation (1) is determined by Equation (2):

    X*=S.sub.r (D)/q.sub.s.sup.max                             (2)

where

S_(r) =the concentration of substrate in the feed stream to thefermenter, g/L;

D=the dilution rate, hr⁻¹ ; and

q_(s) ^(max) =the maximum observed specific rate of substrate uptake forthe strain of Zymomonas being used in the continuous fermentation, gglu/g biomass-hr⁻¹ ; (see Table 10).

Experimentally determined values of various growth yield coefficients(Y_(n)) for Z. mobilis strain ATCC 29191 with respect to different solesources of assimilable nitrogen are given in Table 8.

                  TABLE 8                                                         ______________________________________                                        Observed Values of Growth Yields                                              (Z. mobilis ATCC 29191)                                                       Nitrogen Source Growth Yield Y.sub.n                                          ______________________________________                                        Yeast Extract (Difco)                                                                         0.45 g dry biomass/g YE                                       Ammonium Chloride                                                                             1.87 g dry biomass/g NH.sub.4 Cl                              Ammonium Sulphate                                                                             1.52 g dry biomass/g (NH.sub.4).sub.2 SO.sub.4                ______________________________________                                    

Growth yield coefficients (Y_(n)) with respect to nitrogen, phosphorusand potassium were calculated from steady state biomass concentrationsin respectively limited chemostat cultures at a fixed dilution rate of0.15 hr⁻¹, a constant temperature of 30° C. and a pH of 5.5. In eachcase the entering glucose concentration was approximately 100 g/L. Theresults are summarized in Table 9. The value of growth yield withrespect to potassium in influenced by the [Na⁺ ] such that Y_(K)decreases with increasing concentration of Na⁺ in the culture medium.The titrant used to maintain pH was NaOH. Observed values for differentgrowth yields for Z. mobilis are in good agreement with general valuescited in the literature with respect to the elemental composition (%w/w) of bacteria.

                  TABLE 9                                                         ______________________________________                                        Calculated Values of Growth Yields                                            (Z. mobilis ATCC 29191)                                                                    Y.sub.n       Composition                                        Type of      Growth Yield  of Biomass                                         Limiting Nutrient, n                                                                       (g biomass/g atom)                                                                          % w/w                                              ______________________________________                                        Nitrogen (N) 7.1           14                                                 Phosphorus (P.sub.i)                                                                       44            2.3                                                Potassium (K.sup.+)                                                                        33            3.0                                                ______________________________________                                    

The values given in Table 9 can be substituted in Equation (1). It willbe understood that these values may vary with the fermentation systemand operating techniques and should be confirmed by experimentation inthe system under study or in question.

It has been suggested in the literature that the values for q_(s) ^(max)and q_(p) ^(max) are stain specific traits in Z. mobilis. In any event,q_(s) ^(max) and q_(p) ^(max) for the strain of interest can best bedetermined by means of non-carbon limitation under steady-stateconditions in continuous culture in a chemostat. The value for q_(s)^(max) may vary depending on the nature of the limiting nutrient and theparticular strain of Z. mobilis chosen, but q_(s) ^(max) is generallyabout 7 to about 10 g glucose/g cell-hr⁻¹. Experimentally determinedvalues of q_(s) ^(max) for nutrient-limited fermentations by the strainATCC 29191 are given in Table 10.

                  TABLE 10                                                        ______________________________________                                        Observed Average Values of Maximum Specific Rate of Glucose                   Uptake for Nutrient-Limited Fermentation by Strain                            ATCC 29191 in Continuous Culture in a Chemostat                               Type of                                                                       Limiting                                                                              Chemical Identity                                                                            q.sub.s.sup.max                                        Nutrient,                                                                             of Limiting    (g glucose/                                                                              Y.sub.X /n                                  n       Nutrient       biomass-hr.sup.-1)                                                                       (g glu/g of n)                              ______________________________________                                        Nitrogen                                                                              NH.sub.4 Cl    8.3        1.87                                                (NH.sub.4).sub.2 SO.sub.4                                                                    8.3        1.52                                                Yeast Extract (Difco)                                                                        8.3        0.45                                        Potassium                                                                             KCl            7.5        17                                          Phosphate                                                                             KH.sub.2 PO.sub.4                                                                            7.2        10                                          ______________________________________                                    

The values in Table 10 can be substituted in Equation (2), once againsubject to confirmation in the system under study.

The observed q_(s) ^(max) for potassium-limited Z. mobilis strain ATCC29191 has been found to be 7.5 g glucose/g biomass-hr⁻¹, and the valuefor the growth yield (Y_(K)) with respect to KCl has been found to be 17g biomass/g KCl. The observed value for Y_(K) is 33 g biomass/g K⁺,which is equivalent to saying that the biomass is 3% w/w potassium.Equations (1) and (2) can also be used to predict the amount ofpotassium (e.g. as KCl) required to achieve a condition of potassiumlimitation in continuous culture at various values for the concentrationof glucose in the feed stream (S_(r)) and dilution rate (D).

The observed average value for q_(s) ^(max) for a phosphorus-limitedculture of Z. mobilis is 7.2 g glu/g biomass-hr⁻¹ and the growth yieldwith respect to phosphorus (as potassium dihydrogen phosphate) is 10 gbiomass/g KH₂ PO₄. The observed Y_(p) is 44 g biomass/g P, which isequivalent to biomass being 2.3% w/w with respect to its phosphoruscontent. These values can be substituted appropriately into Equations(1) and (2) in order to predict the amount of phosphorus required toachieve a condition of phosphorus-limitation at various values of S_(r)and dilution rate.

The values in Tables 8 and 9 were determined at various values for S_(r)and D. As mentioned previously, because Z. mobilis is sensitive toethanol at concentrations in excess of about 5% (w/v), there is an upperlimit to the practical value of S_(r), namely about 150 g fermentablesugar/L.

The following Examples illustrate working embodiments of this invention.

EXAMPLE 1

Continuous ethanol fermentations were performed in apparatus similar tothat described in the Figure. Bench-top chemostats (Model C30, NewBrunswick Scientific Co. N.J.) were used in which the content workingvolume (V) of 350 ml was established and maintained by means of anattached overflow tube. The culture was agitated by means of a pair ofturbine six blade impellers operating at 200 RPM. The temperature wascontrolled at 30° C. and the pH was monitored using a combination Ingoldelectrode coupled to a Model pH-40 (New Brunswick Scientific) pHanalyzer. The addition of titrant (KOH) was controlled automatically bythe pH controller and maintained at 5.5. The vessel was not sparged withgas of any kind except during start-up when oxygen-free N₂ was used at arate of approximately 0.5 v/v/m.

The chemical composition of the semi-synthetic culture medium isdescribed in Table 7. The concentration of glucose were 20, 60 or 110g/L. Yeast extract obtained from Difco was the sole source ofassimilable nitrogen added to the culture medium (i.e., ammoniumchloride was not added). In order to achieve a condition ofnitrogen-excess growth, 5 g/L yeast extract were added to the basalsalts medium (at all concentrations of glucose). For nitrogen-limitationthe amount of yeast extract added to the salts medium depended on theamount of glucose in the medium such that for media containing 20, 60and 110 g glucose/L, yeast extract in amounts of 0.8, 2.4 and 4.4 g,respectively, were added per liter (L).

Polypropylene glycol 2025 was added to the medium as an antifoamingagent at a concentration of 0.1 ml/L. Media were prepared and autoclavedin 13 L pyrex carbuoys. Sterile culture medium was fed to the fermenterat a constant rate (F) by means of a peristaltic pump such that thedilution rate (calculated as F/V) was 0.15/hr⁻¹. The fermenter wasinoculated (15% v/v) with Z. mobilis ATCC 29191, which had been grownovernight in medium of similar composition in a non-agitated flaskincubated at 30° C. Flow to the fermenter was not commenced until theculture was in late-exponential phase of growth. Growth and biomassconcentration were determined as dry weight of culture collected onpreweighed microporous filters (Millipore Corp., 0.45 μm pore size).Sampling the biomass and weighing the dry cells has been found to bemuch more accurate and reliable than turbidity measurement ormeasurements made by indirect methods. Steady-state was presumed to haveoccurred after a minimum of 4 culture turnovers, a turnover beingequivalent in time to the reciprocal of the dilution rate. Glucose wasdetermined using a YSI Glucose Analyzer (Model 27, Yellow SpringsInstrument Co., Ohio). Ethanol was measured by HPLC (HPX-87H Aminex,300×7.8 mm column, from Bio-Rad, Burlington, Ont. Can.). The culture wasroutinely examined for contamination both by microscopic assessment andby plating on selective diagnostic agar media.

The specific rate of glucose uptake, q_(s), (g glucose consumed/gbiomass-hr⁻¹), was calculated as follows: ##EQU1## where S_(r) and S_(o)represent the concentration of fermentable sugar in the feed reservoirand fermenter effluent, respectively;

D=the dilution rate (hr⁻¹); and

X=the dry weight culture biomass concentration (g/L).

Similarly, the specific rate of ethanol formation, q_(p), (g ethanol/gbiomass-hr⁻¹) was calculated as follows: ##EQU2## where [P] representsthe steady state ethanol concentration.

The results of this experiment are summarized in Table 2.

EXAMPLE 2

The same procedure was followed as in EXAMPLE 1 except the sole sourceof nitrogen was ammonium chloride (no yeast extract was added to themedium and as such it is referred to as a defined salts medium). Table 2shows the amount of ammonium chloride (NH₄ Cl) used at different valuesfor S_(r) with respect to glucose, these being 0.19, 0.59 and 1.10 g NH₄Cl/L for S_(r) glucose values of 20, 60 and 110 g/L, respectively.

EXAMPLE 3

The same procedure was followed as in EXAMPLE 1 except that the solesource of assimilable nitrogen was ammonium sulphate (AS). The amountsadded and the results obtained are shown in Table 2.

EXAMPLE 4

Experiments were performed with Z. mobilis strain ATCC 31821. Theresults were substantially the same as those observed with strain ATCC29191.

EXAMPLE 5

Experiments were performed with Z. mobilis strain ATCC 10988. Theresults were substantially the same as those observed with strain ATCC29191.

EXAMPLE 6

Experiments were performed to show the amount of assimilable nitrogenrequired to achieve nitrogen-limitation as a function of dilution rate.The results are summarized in Table 3. S_(r) was constant at 110 g/L andthe dilution rate was set at 0.1, 0.15 and 2.0 hr⁻¹. The sole sources ofnitrogen were yeast extract (Difco), ammonium chloride and ammoniumsulphate. Although the results shown in Table 3 were obtained withstrain ATCC 29191, substantially similar results were observed with bothATCC 31821 and ATCC 10988.

EXAMPLE 7

Table 4 summarizes the results of an experiment with ATCC 29191 toillustrate the effect of end-product (ethanol) inhibition on the generalformula for predicting fermentation performance under conditions ofnitrogen excess and nitrogen limitation. Even when the continuousfermenter was operated near its upper limit with respect to ethanolconcentration, the specific activities (q_(s) and q_(p)) of the culturewere improved by imposing the condition of nitrogen limitation.

EXAMPLE 8

Experiments were performed to show the amount of potassium required toachieve potassium-limitation as a function of glucose concentration at aconstant dilution rate for ATCC 29191. D was constant at 0.15 hr⁻¹, thepH was controlled with NaOH at 5.5 and S_(r) was set at 20, 60 and 110g/L. The sole source of potassium was KCl. The concentration of KCl andresults obtained are summarized in Table 5.

EXAMPLE 9

Experiments were performed to show the amount of assimilable phosphorus,as KH₂ PO₄, required at various sugar concentrations to achieve maximalrate of sugar utilization and ethanol production by Z. mobilis strainATCC 29191, in continuous culture in a chemostat at a fixed dilutionrate of 0.15 hr⁻¹. A pH of 5.5 was maintained with KOH. Theconcentrations of KH₂ PO₄ and the results obtained are shown in Table 6.

Effect of Temperature on Nutrient-Limited Fermentation

Microbial growth and product formation are the result of a complexseries of biochemical reactions that are temperature dependent.Zymomonas strains have a broad range of temperatures within whichmetabolic processes will occur and an optimum temperature range withinwhich the rate of product formation is maximized. As the temperature isincreased toward the optimum temperature, the rate of product formationincreases. Above the optimum temperature, the rate of product formationrapidly declines, due in part to an increasing cell death rate andreduced cell growth rate. Lower biomass level translates to incompletefermentation in a continuous system unless the dilution rate is adjustedappropriately downwardly. This is because, at relatively high substrateconcentrations in the fermenter feed, the specific rate of substrateuptake will increase with increasing temperature, but the reducedbiomass decreases the capacity of the fermenter to process the samesubstrate load. Heretofore, the optimum temperature was not exceededwhen the object was to obtain maximum conversion of substrate to productin the least possible time.

The effect of temperature on the maximum specific growth rate (u_(max))of Z. mobilis strain ATCC 29191 in batch culture has been reported inthe literature and is shown in Table 11. The culture medium contained 2%(w/v) glucose.

                  TABLE 11                                                        ______________________________________                                        The Effect of Temperature on the Maximum Specific                             Growth Rate of Z. mobilis ATCC 29191 in                                       Batch Culture (2% glu and pH 5.5)                                                    Temperature                                                                            max                                                                  (°C.)                                                                           (hr.sup.-1)                                                   ______________________________________                                               30       0.27                                                                 33       0.38                                                                 36       0.26                                                          ______________________________________                                    

The data in Table 11 show that as the temperature in the culture mediumwas increased from 30° C. to 33° C., the maximum specific growth rateincreased, but with a further increase in temperature from 33° C. to 36°C., the maximum specific growth rate declined. Thus, the optimumfermentation temperature for this system was about 33° C. Cell growthwas inhibited above this temperature.

While increasing temperature affects cell growth as shown in Table 11,it has now been found that increasing temperature also affects substrateconversion and product formation. Table 12 shows the effect ofincreasing temperature on performance of a carbon-limited continuousfermentation by Z. mobilis strain ATCC 29191 in a chemostat at aconstant dilution rate of 0.19 hr⁻¹. The substrate was fed to thechemostat as an aqueous solution containing 2% (w/v) glucose.

                  TABLE 12                                                        ______________________________________                                        Effect of Increasing Temperature on Performance of                            Carbon-limited Continuous Fermentation by Z. mobilis                          ATCC 29191 at Constant Dilution Rate (D = 0.19 hr.sup.-1 ;                    2% glu; pH 5.5)                                                                        30° C.                                                                            33° C.                                                                         36° C.                                     ______________________________________                                        S.sub.r (g/L)                                                                            20.7         20.7    20.7                                          S.sub.o (g/L)                                                                            --           0.1     0.5                                           X (g/L)    0.65         0.55    0.45                                          q.sub.s (g/g-hr.sup.-1)                                                                  5.9          7.25    8.8                                           q.sub.p (g/g-hr.sup.-1)                                                                  2.80         3.41    4.14                                          Y.sub.p/s (g/g)                                                                          0.47         0.47    0.47                                          ______________________________________                                    

In the continuous fermentations reported in Table 12, the glucoseconcentration in the feed to the fermenter was maintained constant at20.7 g/L. When the temperature in the fermentation medium was increasedfrom 30° C. to 33° C., the biomass concentration (X) in the fermenterdecreased, but this decrease was compensated for by an increase in thespecific rate of glucose uptake (q_(s)). It will be observed, however,that glucose began to appear in the fermenter effluent (i.e. S_(o) =0.1g/L) at 33° C.

When the temperature in the fermentation medium was further increasedfrom 33° C. to 36° C., once again the biomass concentration in thefermenter declined, this time from 0.55 g/L to 0.45 g/L, but the declinewas offset by a further increase in the specific rate of glucose uptake(q_(s)). The conversion of glucose to ethanol was incomplete and theconcentration of glucose in the effluent (S_(o)) increased to 0.5 g/L.While the yield coefficient (Y_(p/s)) remained constant at 0.47 g/g, thepresence of unconverted glucose in the effluent was unacceptable.

The effect of increasing temperature on the performance of K⁺ -limitedcontinuous fermentation by Z. mobilis strain ATCC 29191 in a chemostatat a constant dilution rate of 0.15 hr⁻¹ is shown in Table 13. Potassiumwas supplied as KCl at a concentration of 0.13 g/L.

                  TABLE 13                                                        ______________________________________                                        Effect of Increasing Temperature on Performance of                            K.sup.+ -limited Continuous Fermentation by Z. mobilis                        ATCC 29191 at Constant Dilution Rate (D = 0.15 hr.sup.-1)                                    30° C.                                                                       35° C.                                            ______________________________________                                        S.sub.r g/L      110     110                                                  [KCl] g/L        0.13    0.13                                                 X (g/L)          2.2     1.48                                                 q.sub.s (g/g-hr.sup.-1)                                                                        7.5     8.9                                                  Y.sub.KCl (g/g)  17      11.5                                                 S.sub.o (g/L)    --      22                                                   ______________________________________                                    

The data in Table 13 show that increasing the temperature in thefermentation medium from 30° C. to 35° C. at a constant glucoseconcentration in the feed stream of 110 g/L resulted in a decrease inthe biomass concentration and an increase in the specific rate ofglucose uptake (q_(s)). In this case, however, the yield coefficient(Y_(n) where n=KCl) declined from 17 g/g KCl to 11.5 g/g KCl and theglucose concentration in the effluent increased from 0 g/L to 22 g/L.These changes in system performance would adversely affect processeconomics in a commercial operation.

Table 14 shows the effect of increasing temperature on performance of aK⁺ -limited continuous fermentation by strain ATCC 29191 in a chemostatat varying dilution rates. The substrate was fed to the fermenter as anaqueous solution containing 2% (w/v) glucose and at a fixed flow rate.Potassium was supplied as KCl at a concentration of 0.1 g/L.

                  TABLE 14                                                        ______________________________________                                        The Effect of Temperature on Kinetics of                                      K.sup.+ -limited Z. mobilis Strain ATCC 29191                                                                    q.sub.s                                    Temp. S.sub.r S.sub.o D      X     (g/g- q.sub.p                              (°C.)                                                                        (g/L)   (g/L)   (hr.sup.-1)                                                                          (g/L) hr.sup.-1)                                                                          (g/g-hr.sup.-1)                      ______________________________________                                        30.0  100     18.3    0.155  1.70  7.40  3.48                                 32.8  100     10.6    1.157  1.68  8.20  3.85                                 35.0  100     34.8    0.160  1.15  8.90  4.0                                  ______________________________________                                    

Increasing the temperature by 2°-3° C. resulted in more conversion ofglucose to ethanol, i.e. from approximately 82% to 90%, as judged by thedecrease in effluent glucose (S_(o)). However, further increase intemperature caused more glucose to appear in the effluent and theconversion fell to 65%. At 35° C. the morphology of the culture changeddramatically becoming very filamentous. The result of operation at 35°C. was a reduced cell density, and even though the q_(p) was higher, thereduced biomass could not handle the sugar load.

The effect of increasing temperature on the performance of a K⁺ -limitedcontinuous fermentation by Z. mobilis according to this invention isshown in Table 15. The fermentation was carried out by Z. mobilis strainATCC 29191 in a chemostat at a constant dilution rate of 0.15 hr⁻¹.Potassium was supplied as KCl at concentrations indicated.

                  TABLE 15                                                        ______________________________________                                        Effect of Increasing Temperature on Performance of                            K.sup.+ -limited Continuous Fermentation by Z. mobilis                        Strain ATCC 29191 at Constant Dilution Rate (D = 0.15 hr.sup.-1)                       30° C.                                                                            35° C.                                                                         35° C.                                     ______________________________________                                        S.sub.r g/L                                                                              110          110     110                                           [KCl] g/L  0.13         0.13    0.16                                          X (g/L)    2.2          1.48    1.85                                          q.sub.s (g/g-hr.sup.-1)                                                                  7.5          8.9     8.9                                           Y.sub.KCl (g/g)                                                                          17           11.5    11.5                                          S.sub.o (g/L)                                                                            --           22      --                                            ______________________________________                                    

The concentration of substrate to the fermenter was the same in allcases, i.e. 110 glucose/L. Comparing column 2 with column 3 in Table 15,when the fermentation temperature was increased from 30° C. to 35° C.,the biomass concentration (X) decreased from 2.2 g/L to 1.48 g/L, whilethe specific rate of glucose uptake (q_(s)) increased from 7.5 to 8.9g/g-hr⁻¹. The amount of glucose in the effluent (S_(o)) also increasedfrom 0 to 22 g glucose/L, which was commercially unacceptable.

Comparing column 2 with column 4 in Table 15, it is seen that byincreasing the concentration of the limiting nutrient according to thisinvention, i.e. [KCl] in this case, when the temperature was increasedfrom 30° C. to 35° C., the biomass concentration (X) in the fermenterdecreased from 2.2 g/L to 1.85 g/L while the specific rate of glucoseuptake (q_(s)) increased from 7.5 to 8.9 g/g-hr⁻¹. However, there wassubstantially no glucose in the effluent from the fermenter when theconcentration of the limiting nutrient was properly controlled, i.e.S_(o) =O.

These results demonstrate that this embodiment of the invention makes itpossible to improve the performance of Zymomonas in continuous ethanolfermentation at increased temperatures. The specific rate of substrateuptake can be maintained, and even increased, at fermentationtemperatures of about 33° to about 37° C. even though there is a lowerbiomass concentration in the fermenter. These results can be achievedwithout substantial amounts of substrate in the effluent from thefermenter. These results are made possible by carrying out continuousethanol fermentation with Zymomonas strains under nutrient-limitedconditions, where the limiting nutrient is nitrogen, potassium orphosphorus. The concentration of the limiting nutrient in thefermentation medium is increased with increasing temperature anddecreased with decreasing temperature.

In summary, the processes of this invention make it possible to carryout a continuous fermentation by Z. mobilis at reduced biomassconcentration in the fermenter, increased specific rate of substrateuptake, increased specific rate of product formation and substantiallywithout substrate in the effluent by regulating the amount of limitingnutrient. The processes of this invention take into account theunexpected decrease in growth yield with respect to the limitingnutrient and adjust the amount of the nutrient in the mediumaccordingly. The fermentation system operates efficiently at a hightemperature, such as 35° C., with respect to fermentation capacity, andat a higher specific rate of substrate uptake and a higher specific rateof product formation with a lower biomass concentration in thefermenter. As previously discussed, this can be of considerableadvantage in designing and operating a continuous fermentation with cellrecycle where the productivity is typically limited by the concentrationof biomass that can be handled by the recycle device be it a filtrationsystem, centrifuge or settler.

What is claimed is:
 1. A continuous process for the production ofethanol, which comprises cultivating in submerged culture underanaerobic conditions an organism of the Zymomonas genus in an aqueousnutrient medium containing potassium and assimilable carbon, nitrogenand phosphorus until a recoverable quantity of ethanol isproduced;wherein said nutrient is limited in one or more of thenutrients selected from the group consisting of nitrogen, potassium andphosphorus such that the rate of growth of said organism is limited bythe availability of the limited nutrient; and wherein said biomassexpresses its maximal value for both q_(s) and q_(p) under the conditionof nutrient limitation; said process being conducted as anutrient-limited fermentation and at a lower biomass concentration and ahigher specific rate of ethanol formation than a similar processconducted with a nutrient medium that contains said nutrients in excess,and wherein each of said processes is carried out at the samefermentation temperature, dilution rate and concentration of assimilablecarbon.
 2. Process according to claim 1 wherein fermentation isconducted at a temperature of about 27° C. to about 37° C.
 3. Processaccording to claim 1 wherein fermentation is conducted in a fermentationmedium having a pH of about 4.5 to about 6.5.
 4. Process according toclaim 1 wherein fermentation is conducted at a temperature of about 30°C. and a pH of about 5.5.
 5. Process according to claim 1 wherein thenutrient medium contains an approximate amount of limiting nutrientaccording to the following relationships ##EQU3##
 6. Process accordingto claim 1 wherein said organism is a Z. mobilis strain selected fromthe group consisting of ATCC 10988, ATCC 29191, ATCC 31821 and ATCC31822.
 7. Process according to claim 1 wherein said organism is Z.mobilis strain ATCC
 29191. 8. Process according to claim 1 wherein saidsubstrate is comprised of glucose.
 9. Process according to claim 8wherein substrate concentration in the fermentation medium is about 100g/L to about 180 g/L.
 10. Process according to claim 9 whereinconcentration of substrate in effluent from the process is less thanabout 5% S_(r).
 11. Process according to claim 9 wherein effluent fromthe process is substantially free of substrate.
 12. Process according toclaim 1 wherein concentration of ethanol in the fermentation medium isabout 50 g/L to about 60 g/L.
 13. Process according to claim 1 whereinfermentation is carried out in a fermenter with cell recycle. 14.Process according to claim 1 wherein said nitrogen is derived fromammonium chloride, ammonium sulphate or mixtures thereof.
 15. Processaccording to claim 1 wherein said phosphorus is derived from KH₂ PO₄.16. Process according to claim 1 wherein said potassium is derived fromKCl.
 17. Process according to claim 4 wherein said organism is Z.mobilis strain ATCC
 29191. 18. Process according to claim 17 whereinsaid substrate is comprised of glucose.
 19. Process according to claim18 wherein substrate concentration in the fermentation medium is about100 g/L to about 180 g/L.
 20. Process according to claim 19 whereineffluent from the process is substantially free of substrate. 21.Process according to claim 20 wherein concentration of ethanol in thefermentation medium is about 50 g/L to about 60 g/L.
 22. Processaccording to claim 21 wherein fermentation is carried out in a fermenterwith cell recycle.